Experimental investigation of the cutting forces and edge chipping in ultrasonic-assisted drilling of soda glass

Ultrasonic-assisted drilling (UAD) is a promising technology used for machining difficult-to-cut materials. In this paper, experimental investigations were conducted to study the drilling forces and edge chipping for soda glass using diamond abrasive tools. Cutting fluid was used at different levels of feed rate, spindle speed, and tool concentrations. The thrust force, torque, and edge chipping parameters (width, depth, and angle) at entrance and exit sides of the drilled holes were evaluated. Statistical analysis was carried out to support the experimental findings, optimize the process responses, and construct the mean effect plots and interactions of the process parameters. The results show that the thrust force increases when using normal tool concentration, lower spindle speeds, and higher feed rates. The normal concentration, low spindle speed, and high feed rate decrease the exit chipping width. The theoretical analysis proves that the chipping force is less than the impact force and they are not correlated.